TEAM WELDER TIG 180 DC User manual

Operating instructions

Welding machine

TIG 180 DC

299-020100-TWD01

18.03.2016

General information

CAUTION

Read the operating instructions!

The operating instructions provide an introduction to the safe use of the products.

•Read the operating instructions for all system components.

•Observe the applicable accident prevention regulations.

•Observe all country-specific statutory provisions.

•Have confirmed by signature if necessary.

In the event of queries on installation, commissioning, operation or special conditions at the

installation site, or on usage, please contact your sales partner or our

customer service department on +49 2623 9276400.

A list of authorised sales partners can be found at www.teamwelder.com.

Liability in conjunction with the operation of this system is explicitly limited to the functioning of

the system. Any further liability, regardless of which type, is explicitly excluded. This liability

disclaimer is regarded as having been accepted by the user when the system is commissioned.

The manufacturer can neither monitor the compliance with these instructions nor the conditions

and methods employed during the installation, operation, use and maintenance of the machine.

An incorrectly performed installation can lead to material damage and injure persons as a result.

Therefore, we assume no responsibility or liability for losses, damages or costs arising from

erroneous installation, improper operation or incorrect use and maintenance, or any

consequences in conjunction thereof.

TEAMWELDER Germany GmbH

Sälzerstraße 20a

D-56235 Ransbach-Baumbach

Deutschland / Germany

The copyright to this document remains the property of the manufacturer.

Reprinting, including extracts, only permitted with written approval.

The content of this document has been prepared and reviewed with all reasonable care. The information

provided is subject to change; errors excepted.

Contents

Notes on the use of these operating instructions

299-020100-TWD01

18.03.2016

1 Contents

1Contents..................................................................................................................................................3

2Safety instructions.................................................................................................................................5

2.1 Notes on the use of these operating instructions ..........................................................................5

2.2 Explanation of icons.......................................................................................................................6

2.3 General..........................................................................................................................................7

2.4 Transport and installation ............................................................................................................11

2.4.1 Ambient conditions.......................................................................................................12

2.4.1.1 In operation...................................................................................................12

2.4.1.2 Transport and storage...................................................................................12

3Intended use.........................................................................................................................................13

3.1 Documents which also apply.......................................................................................................13

3.1.1 Warranty.......................................................................................................................13

3.1.2 Declaration of Conformity.............................................................................................13

3.1.3 Welding in environments with increased electrical hazards.........................................13

3.1.4 Service documents (spare parts and circuit diagrams)................................................13

3.1.5 Calibration/Validation ...................................................................................................13

4Machine description –quick overview ..............................................................................................14

4.1 Front view ....................................................................................................................................14

4.2 Rear view.....................................................................................................................................15

4.3 Machine control –Operating elements........................................................................................16

4.3.1 Welding data display ....................................................................................................17

5Design and function.............................................................................................................................18

5.1 General........................................................................................................................................18

5.2 Machine cooling...........................................................................................................................18

5.3 Workpiece lead, general..............................................................................................................19

5.4 Transport and installation ............................................................................................................19

5.4.1 Adjusting the length of the carrying strap.....................................................................19

5.5 Mains connection.........................................................................................................................20

5.5.1 Mains configuration ......................................................................................................20

5.6 TIG welding..................................................................................................................................21

5.6.1 Welding torch and workpiece line connection..............................................................21

5.6.2 5-pole control lead........................................................................................................22

5.6.3 Shielding gas supply (shielding gas cylinder for welding machine).............................22

5.6.3.1 Connecting the shielding gas supply ............................................................23

5.6.3.2 Setting the shielding gas quantity.................................................................24

5.6.4 Welding task selection..................................................................................................25

5.6.5 Arc ignition....................................................................................................................26

5.6.5.1 HF ignition.....................................................................................................26

5.6.5.2 Liftarc ignition................................................................................................26

5.6.6 TIG automatic cut-out...................................................................................................26

5.6.7 Function sequences/operating modes .........................................................................27

5.6.7.1 Legend..........................................................................................................27

5.6.7.2 TIG non-latched operation............................................................................28

5.6.7.3 TIG latched operation....................................................................................29

5.6.8 Welding torch (operating variants) ...............................................................................30

5.6.8.1 Tap torch trigger (tapping function)...............................................................30

5.6.9 Torch mode and up/down speed setting......................................................................31

5.6.9.1 Standard TIG torch (5-pole)..........................................................................32

5.6.10 Average value pulse welding........................................................................................34

5.6.11 Expert menu (TIG)........................................................................................................36

5.7 MMA welding ...............................................................................................................................37

5.7.1 Connecting the electrode holder and workpiece lead..................................................37

5.7.2 Welding task selection..................................................................................................38

5.7.3 Hotstart.........................................................................................................................38

5.7.4 Arcforce........................................................................................................................38

Contents

Notes on the use of these operating instructions

299-020100-TWD01

18.03.2016

5.7.5 Antistick.........................................................................................................................39

5.7.6 Average value pulse welding........................................................................................39

5.7.7 Expert menu (MMA)......................................................................................................41

5.8 Remote control.............................................................................................................................42

5.8.1 TW-RT1 19POL............................................................................................................42

5.8.2 Power-saving mode (Standby).....................................................................................42

5.9 Machine configuration menu........................................................................................................42

6Maintenance, care and disposal.........................................................................................................44

6.1 General.........................................................................................................................................44

6.2 Maintenance work, intervals ........................................................................................................44

6.2.1 Daily maintenance tasks...............................................................................................44

6.2.1.1 Visual inspection ...........................................................................................44

6.2.1.2 Functional test...............................................................................................44

6.2.2 Monthly maintenance tasks..........................................................................................44

6.2.2.1 Visual inspection ...........................................................................................44

6.2.2.2 Functional test...............................................................................................44

6.2.3 Annual test (inspection and testing during operation)..................................................45

6.3 Disposing of equipment................................................................................................................45

6.3.1 Manufacturer's declaration to the end user..................................................................45

6.4 Meeting the requirements of RoHS..............................................................................................45

7Rectifying faults....................................................................................................................................46

7.1 Checklist for rectifying faults........................................................................................................46

7.2 Machine faults (error messages) .................................................................................................47

7.3 Resetting welding parameters to the factory settings..................................................................48

7.4 Display machine control software version....................................................................................48

7.5 Dynamic power adjustment..........................................................................................................48

8Technical data.......................................................................................................................................49

8.1 TIG 180 DC..................................................................................................................................49

9Accessories ..........................................................................................................................................50

9.1 Internet.........................................................................................................................................50

Safety instructions

Notes on the use of these operating instructions

299-020100-TWD01

18.03.2016

2 Safety instructions

2.1 Notes on the use of these operating instructions

DANGER

Working or operating procedures which must be closely observed to prevent imminent

serious and even fatal injuries.

•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.

•The hazard is also highlighted using a symbol on the edge of the page.

WARNING

Working or operating procedures which must be closely observed to prevent serious

and even fatal injuries.

•Safety notes include the "WARNING" keyword in the heading with a general warning

symbol.

•The hazard is also highlighted using a symbol in the page margin.

CAUTION

Working or operating procedures which must be closely observed to prevent possible

minor personal injury.

•The safety information includes the "CAUTION" keyword in its heading with a general

warning symbol.

•The risk is explained using a symbol on the edge of the page.

CAUTION

Working and operating procedures which must be followed precisely to avoid damaging

or destroying the product.

•The safety information includes the "CAUTION" keyword in its heading without a general

warning symbol.

•The hazard is explained using a symbol at the edge of the page.

Special technical points which users must observe.

Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet

points, e.g.:

•Insert the welding current lead socket into the relevant socket and lock.

Safety instructions

Explanation of icons

299-020100-TWD01

18.03.2016

2.2 Explanation of icons

Symbol

Description

Special technical points which users must observe.

Correct

Wrong

Press

Do not press

Press and keep pressed

Turn

Switch

Switch off machine

Switch on machine

ENTER

enter the menu

NAVIGATION

Navigating in the menu

EXIT

Exit the menu

4 s

Time display (example: wait 4s/press)

Interruption in the menu display (other setting options possible)

Tool not required/do not use

Tool required/use

Safety instructions

General

299-020100-TWD01

18.03.2016

2.3 General

DANGER

Electromagnetic fields!

The power source may cause electrical or electromagnetic fields to be produced which

could affect the correct functioning of electronic equipment such as IT or CNC devices,

telecommunication lines, power cables, signal lines and pacemakers.

•Observe the maintenance instructions - See 6 chapter!

•Unwind welding leads completely!

•Shield devices or equipment sensitive to radiation accordingly!

•The correct functioning of pacemakers may be affected (obtain advice from a doctor if

necessary).

Do not carry out any unauthorised repairs or modifications!

To avoid injury and equipment damage, the unit must only be repaired or modified by

specialist, skilled persons!

The warranty becomes null and void in the event of unauthorised interference.

•Appoint only skilled persons for repair work (trained service personnel)!

Electric shock!

Welding machines use high voltages which can result in potentially fatal electric shocks

and burns on contact. Even low voltages can cause you to get a shock and lead to

accidents.

•Do not touch any live parts in or on the machine!

•Connection cables and leads must be free of faults!

•Switching off alone is not sufficient!

•Place welding torch and stick electrode holder on an insulated surface!

•The unit should only be opened by specialist staff after the mains plug has been

unplugged!

•Only wear dry protective clothing!

•Wait for 4 minutes until the capacitors have discharged!

WARNING

Risk of injury due to radiation or heat!

Arc radiation results in injury to skin and eyes.

Contact with hot workpieces and sparks results in burns.

•Use welding shield or welding helmet with the appropriate safety level (depending on the

application)!

•Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant

regulations in the country in question!

•Protect persons not involved in the work against arc beams and the risk of glare using

safety curtains!

Explosion risk!

Apparently harmless substances in closed containers may generate excessive pressure

when heated.

•Move containers with inflammable or explosive liquids away from the working area!

•Never heat explosive liquids, dusts or gases by welding or cutting!

Safety instructions

General

299-020100-TWD01

18.03.2016

WARNING

Smoke and gases!

Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent

vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to

the ultraviolet radiation of the arc!

•Ensure that there is sufficient fresh air!

•Keep solvent vapour away from the arc beam field!

•Wear suitable breathing apparatus if appropriate!

Fire hazard!

Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts

and hot slag produced during the welding process.

Stray welding currents can also result in flames forming!

•Check for fire hazards in the working area!

•Do not carry any easily flammable objects such as matches or lighters.

•Keep appropriate fire extinguishing equipment to hand in the working area!

•Thoroughly remove any residue of flammable substances from the workpiece before

starting welding.

•Only continue work on welded workpieces once they have cooled down.

Do not allow to come into contact with flammable material!

•Connect welding leads correctly!

Risk of accidents due to non-compliance with the safety instructions!

Non-compliance with the safety instructions can be fatal!

•Carefully read the safety instructions in this manual!

•Observe the accident prevention regulations and any regional regulations!

•Inform persons in the working area that they must comply with the regulations!

Danger when coupling multiple power sources!

Coupling multiple power sources in parallel or in series has to be carried out by

qualified personnel and in accordance with the manufacturer's guidelines. Before

bringing the power sources into service for arc welding operations, a test has to verify

that they cannot exceed the maximum allowed open circuit voltage.

•Connection of the machine may be carried out by qualified personnel only!

•When decommissioning individual power sources, all mains and welding current leads have

to be safely disconnected from the welding system as a whole. (Danger due to inverse

voltages!)

•Do not couple welding machines with pole reversing switch (PWS series) or machines for

AC welding, as a minor error in operation can cause the welding voltages to be combined.

CAUTION

Noise exposure!

Noise exceeding 70 dBA can cause permanent hearing damage!

•Wear suitable ear protection!

•Persons located within the working area must wear suitable ear protection!

Safety instructions

General

299-020100-TWD01

18.03.2016

CAUTION

Obligations of the operator!

The respective national directives and laws must be observed for operation of the

machine!

•National implementation of the framework directive (89/391/EWG), as well as the

associated individual directives.

•In particular, directive (89/655/EWG), on the minimum regulations for safety and health

protection when staff members use equipment during work.

•The regulations regarding work safety and accident prevention for the respective country.

•Setting up and operating the machine according to IEC 60974-9.

•Check at regular intervals that users are working in a safety-conscious way.

•Regular checks of the machine according to IEC 60974-4.

Damage due to the use of non-genuine parts!

The manufacturer's warranty becomes void if non-genuine parts are used!

•Only use system components and options (power sources, welding torches, electrode

holders, remote controls, spare parts and replacement parts, etc.) from our range of

products!

•Only insert and lock accessory components into the relevant connection socket when the

machine is switched off.

Damage to the machine due to stray welding currents!

Stray welding currents can destroy protective earth conductors, damage equipment and

electronic devices and cause overheating of components leading to fire.

•Make sure all welding leads are securely connected and check regularly.

•Always ensure a proper and secure electrical connection to the workpiece!

•Set up, attach or suspend all conductive power source components like casing, transport

vehicle and crane frames so they are insulated!

•Do not place any other electronic devices such as drillers or angle grinders, etc., on the

power source, transport vehicle or crane frames unless they are insulated!

•Always put welding torches and electrode holders on an insulated surface when they are

not in use!

Mains connection

Requirements for connection to the public mains network

High-performance machines can influence the mains quality by taking current from the mains

network. For some types of machines, connection restrictions or requirements relating to the

maximum possible line impedance or the necessary minimum supply capacity at the interface

with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,

attention is also drawn to the machines' technical data. In this case, it is the responsibility of

the operator, where necessary in consultation with the mains network operator, to ensure that

the machine can be connected.

Safety instructions

General

299-020100-TWD01

18.03.2016

CAUTION

EMC Machine Classification

In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic

compatibility classes - See 8 chapter:

Class A machines are not intended for use in residential areas where the power supply comes

from the low-voltage public mains network. When ensuring the electromagnetic compatibility of

class A machines, difficulties can arise in these areas due to interference not only in the supply

lines but also in the form of radiated interference.

Class B machines fulfil the EMC requirements in industrial as well as residential areas,

including residential areas connected to the low-voltage public mains network.

Setting up and operating

When operating arc welding systems, in some cases, electro-magnetic interference can occur

although all of the welding machines comply with the emission limits specified in the standard.

The user is responsible for any interference caused by welding.

In order to evaluate any possible problems with electromagnetic compatibility in the

surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)

•Mains, control, signal and telecommunication lines

•Radios and televisions

•Computers and other control systems

•Safety equipment

•The health of neighbouring persons, especially if they have a pacemaker or wear a hearing

aid

•Calibration and measuring equipment

•The immunity to interference of other equipment in the surrounding area

•The time of day at which the welding work must be carried out

Recommendations for reducing interference emission

•Mains connection, e.g. additional mains filter or shielding with a metal tube

•Maintenance of the arc welding equipment

•Welding leads should be as short as possible and run closely together along the ground

•Potential equalization

•Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,

it should be connected by means of suitable capacitors.

•Shielding from other equipment in the surrounding area or the entire welding system

Table of contents

Other TEAM WELDER Welding System manuals

TEAM WELDER

TEAM WELDER Plasma CUT 65 User manual

TEAM WELDER

TEAM WELDER MIG drive Synergic puls User manual

TEAM WELDER

TEAM WELDER MIG 250 S User manual

TEAM WELDER

TEAM WELDER TIG 180 AC/DC puls User manual

TEAM WELDER

TEAM WELDER MIG 302 S SYNERGIC User manual

TEAM WELDER

TEAM WELDER TIG 180 AC/DC User manual

TEAM WELDER

TEAM WELDER MMA 160 User manual

Popular Welding System manuals by other brands

Berner

Berner PLASMACUT 54 instruction manual

Pro Spot

Pro Spot PR-155 Assembly instructions

Forney

Forney 210 operating manual

Thermal Arc

Thermal Arc 400S operating manual

Lincoln Electric

Lincoln Electric HANDYMIG 170I Operator's manual

GYS

GYS PROTIG 201 AC/DC Original instructions

TAFA

TAFA 30*8B35 owner's manual

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Technical specifications

ESAB

ESAB Buddy Arc 145 instruction manual

CIGWELD

CIGWELD 636804 use instructions

Red-D-Arc

Red-D-Arc DC-400 Operator's manual

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 owner's manual

Elettro

Elettro HI-MIG 3000 SYNERGIC instruction manual

WIA

WIA Weldmatic 270 CP132-2 Operator's manual

Sonics

Sonics H520T instruction manual

Miller

Miller Big Blue 400D owner's manual

NewArc

NewArc RT2000 Operational manual

Hypertherm

Hypertherm powermax1000 Operator's manual